Toe protection sandal

ABSTRACT

A sandal including a molded rubber outsole configured to support a lower surface of a foot including a heel, midfoot, and a forefoot; a toe cap extending from the outsole and configured to cover a top of at least a portion of the forefoot, the toe cap molded integrally with the outsole; and a plurality of sandal straps fixed to the outsole to retain the sandal on the foot, at least one of the sandal straps fixed to the toe.

FIELD OF THE INVENTION

The invention relates to footwear, and more particularly the inventionrelates to a sandal with a toe cap for toe protection, and a method ofmanufacturing the same.

DESCRIPTION OF THE RELATED ART

Sandals are available in a wide variety of constructions. A conventionalsandal includes a strapping system secured to a sole. The sole engagesthe wearer's foot and forms the wear surface of the sandal. Meanwhile,the strapping system secures the sole to the wearer's foot, typicallyusing separate ankle, heel and forefoot straps.

The straps are secured to the sole primarily using one of two differentconstruction techniques. The first of these techniques is a stitchingtechnique in which the lower ends of the straps or the posts arestitched directly to the sole. This technique is relatively inexpensive,however, it may not provide the durability needed for certainapplications. Further, this technique is essentially limited to use withstrap materials that are capable of being stitched, such as leather,woven or textile straps. This construction technique, however, is notwell suited for use with rigid, non-pliable materials. In someapplications, the stitching is replaced by staples or tacks. In general,these alternative constructions suffer from the same problems as thestitched construction.

A second technique for securing the straps to the sole is an adhesiveconstruction in which the strap ends are cemented or adhesively securedto the sole. The adhesive construction generally provides improveddurability and is well suited for use with relatively rigid postmaterials, such as thermoplastic elastomers.

On the other hand, shoes and boots are traditionally fabricated byshaping the footwear over a last. A last is a three-dimensional shape ofthe inside cavity of a boot or shoe. The upper and sole are generallyplaced over the last in pieces or assemblies and secured together. Apreassembled component upper consists of various layers of fabric and/orleather material sewn and/or glued together to form the upper or aportion of the upper shoe.

The rigidity and flexibility characteristics of the footwear areachieved by interposing the various layers of materials having suitablemechanical properties in specific regions of the footwear. In onetypical assembly process, an insole is positioned on the top portion ofthe inverted last, which represents the inside bottom part of thearticle of footwear and the preassembled fabric component is thenpositioned over the last. The fabric components are stretched over thelast and pushed over the insole to conform to the specific shape of thelast and then nailed, tacked, and/or glued to the insole to maintain thedesired shape. Often rigid plastic components are added to the soleconstruction to increase the strength and support of the footwear inspecific areas. The footwear is usually completed with a midsole orcushioning and then an outsole nailed, tacked and/or glued to theassembly of components on the last.

Some of the sandal constructions are intended to solve specific problemscreated by certain environments. For example, one involved in activitiesaround the water needs a sandal which provide adequate support, iscomfortable and remains secure even after walking substantial distances.On the other hand, one involved in light hiking or other activitiesexposing the sandal to extreme terrain might want more of shoe with asandal like feel and freedom. However, with traditional sandalmanufacturing and assembly, the consistency of the sandal has variedfrom sandal to sandal. Thus, the consumer could not always be guaranteedthat each size 9 would fit the same.

Accordingly, what is need is a sandal that is manufactured and assembledlike a shoe for consistency and standardization of sizing. In addition,it would be desirable for a sandal having shoe like construction thatnot only provides durability and protection to the wearer's footincluding toe protection but also the comfort and style of a sandal.

SUMMARY OF THE INVENTION

The present invention relates to footwear, and more particularly theinvention relates to a sandal with a toe cap for toe protection, and amethod of manufacturing the same.

In accordance with one aspect of the present invention, a sandalincluding a molded rubber outsole configured to support a lower surfaceof a foot including a heel, midfoot, and a forefoot; a toe cap extendingfrom the outsole and configured to cover a top of at least a portion ofthe forefoot, the toe cap molded integrally with the outsole; and aplurality of sandal straps fixed to the outsole to retain the sandal onthe foot, at least one of the sandal straps fixed to the toe cap.

In accordance with another aspect of the present invention, a sandalincluding a molded rubber outsole configured to support a lower surfaceof a foot including a heel, midfoot, and a forefoot; a toe cap extendingfrom the outsole and configured to cover a top of at least a portion ofthe forefoot, the toe cap molded integrally with the outsole; and aplurality of sandal straps fixed to the outsole to retain the sandal onthe foot, at least one of the sandal straps fixed to the toe cap.

In accordance with a further aspect of the present invention, a mold formanufacturing an outsole of a sandal, including a bottom plate, thebottom plate configured to form a lower surface of the outsole; an innertoe cap plate, the inner toe cap plate configured to form an uppersurface of the outsole including an inner cavity of a toe cap; and anouter toe cap plate, the outer toe cap plate configured to form an outersurface of the toe cap.

In accordance with another aspect of the present invention, a method forthe production of a molded outsole, the outsole having a toe capextending from the outsole and configured to cover a top of at least aportion of the forefoot, the toe cap molded integrally with the outsole,the method including the steps of placing a first material in a firstmold cavity, the first mold cavity formed between a bottom plate and aninner toe cap plate; closing the first mold cavity; placing the firstmaterial in a second mold cavity, the second mold cavity formed betweenthe bottom plate and an outer toe plate; closing the second mold cavity;and curing the first material to form the outsole.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The invention will now be described in greater detail with reference tothe preferred embodiments illustrated in the accompanying drawings, inwhich like elements bear like reference numerals, and wherein:

FIG. 1 is a perspective view of a sandal according to one embodiment ofthe present invention.

FIG. 2 is an exploded perspective view of the sandal of FIG. 1.

FIG. 3 is a bottom plan view of the inner midsole of the sandal of FIG.1.

FIG. 4 is an exploded perspective view of the sandal of FIG. 1.

FIG. 5 is a top plan view of the sandal of FIG. 1.

FIG. 6 is a cross-sectional view of the sandal of FIG. 5 taken along theline A—A.

FIG. 7 is a cross-sectional view of the sandal of FIG. 5 taken along theline B—B.

FIG. 8 is a bottom plan view of the sandal of FIG. 1

FIG. 9 is a side view of the medial side of the sandal of FIG. 1.

FIG. 10 is a side view of the lateral side of the sandal of FIG. 1.

FIG. 11 is a front view of the toe cap of the sandal of FIG. 1.

FIG. 12 is a back view of the heel of the sandal of FIG. 1.

FIG. 13 is a perspective view of a sandal according to an alternativeembodiment of the present invention.

FIG. 14 is a perspective view of a sandal according to anotherembodiment of the present invention.

FIG. 15 is a perspective view of a sandal according to an alternativeembodiment of the present invention.

FIG. 16 is a perspective view of a mold for molding an outsole accordingto the present invention.

FIG. 17 is a perspective view of the bottom plate and inner toe capplate of the mold for molding an outsole of FIG. 16.

FIG. 18 is a perspective view of the inner toe cap plate and outer toecap plate of the mold for molding an outsole of FIG. 16.

FIG. 19 is a perspective view of a mold for molding an outsole accordingto an alternative embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, wherein like numerals indicate like elements,a sandal in accordance with the present invention is illustrated. Theaccompanying figures illustrate the sandal intended for use on the rightfoot of a wearer. The preferred embodiment also includes a left sandal,such sandal being the mirror image of the right.

Turning to the drawings, a sandal 10 in accordance with one exemplaryembodiment of this invention is shown in FIG. 1. The sandal 10 includesa molded rubber outsole 20 including a toe cap 30 and a plurality ofstraps 60 to retain the sandal on the foot 40.

As shown in FIGS. 1 and 2, the sandal 10 includes a molded rubberoutsole 20 configured to support a lower surface 50 of a foot 40including a heel 42, a midfoot 44, and a forefoot 46. The sandal 10 alsoincludes a toe cap 30 extending from the outsole 20 and configured tocover a top 52 of at least a portion of the forefoot 46. The toe cap 30is molded integrally with the outsole 20. The plurality of sandal straps60 are fixed to the outsole 20 and retain the sandal 10 on the foot 40.In a preferred embodiment of this invention at least one of the sandalstraps 60 is fixed to the toe cap 30.

The lower surface 50 of the foot 40 rests on an upper surface 92 of theinsole 80. The foot 40 also includes the heel 42, midfoot 44, theforefoot 46 and the toes 48.

The insole 80 provides support and comfort and is shaped to match thecontours of the lower surface 50 of the foot 40. In a preferredembodiment, the insole has a raised arch and forefoot, and a slightlyconcave heel. The upper surface 92 of the insole 80 may be textured 94or even contoured 96 to reduce the likelihood of movement between theinsole 80 and the foot 40. For example, a gradual ridge 98 may extendalong the upper surface 92 of the insole 80 between the forefoot 46 andtoe 48 regions of the foot 40.

The insole 80 has a plurality of strap receiving grooves formed in alower surface of the insole 80. The plurality of sandal straps areconfigured to retain the sandal 10 on the foot 40 and are fixed in thestrap receiving grooves 62 between the outsole 20 and the insole 80. Themolded rubber outsole 20 includes the toe cap 30 extending from theoutsole 20 and configured to cover the top surface 52 of at least aportion of the forefoot 46 including the toes 48

The insole 80 preferably includes an anatomic footbed 90 and an innermidsole 100. The anatomic footbed 90 is designed to be substantiallycoextensive with the lower surface 50 of the foot 40. The anatomicallydesigned footbed 90 follows the natural contour of the foot 40 providingadded comfort and support. The anatomic footbed 90 is preferably made ofan anti-odor material such as Aegis™ anti-microbial. The anti-odormaterial such as Aegis™ provides odor fighting protection to assist withextending the life of the sandal 10. However, it can be appreciated thatthe anatomic footbed 90 can be made of leather, a synthetic having aleather like appearance and feel, rubber or nylon depending on the typeof sandal and use therein.

The inner midsole 100 is positioned between the anatomic footbed 90 andthe outsole 20. The inner midsole 100 has a plurality of strap receivinggrooves 62 formed in a side surface 102 of the inner midsole 100. Theplurality of straps 60 extend over the top 54 of the foot 40 into thestrap receiving grooves 62. The straps 60 have a strap end 78 which ispositioned between the inner midsole 100 and the outsole 20. The straps60 are fixed in the strap receiving grooves 62 and between the innermidsole 100 and the outsole 20 by glue, stitching, or other conventionaltechniques.

The strap receiving grooves 62 each have a width 64 substantially equalto a width 74 of the corresponding straps 60 and a depth 66substantially equal to a depth 76 of the corresponding straps 60. Thestrap receiving grooves 62 extend from a top edge 86 of the footbed 90toward a bottom edge 88 of the inner midsole 100. The strap receivinggrooves 62 then extend from the bottom edge 88 of the inner midsole 100towards a center line of a lower surface 104 of the inner midsole 100.The footbed 90 has an upper foot supporting surface 92 which issubstantially even with an upper edge 36 of the side surface 26 of theinner midsole 100.

As shown in FIG. 3, a bottom plan view of the inner midsole 100, thestrap receiving grooves 62 extend from an outer edge of the innermidsole 100 towards a center line of the inner midsole 100. The strapends 78 are fixed in the strap receiving grooves 62 by glue, cement, orstitching or any combination of glue, cement and/or stitching. The strapreceiving grooves 62 provide a pattern, a guide, or index for theassembler to fix the straps to the inner midsole 100. The indexing ofthe straps 60 in the strap receiving grooves 62 provides standardizationor uniformity to allow each and every sandal to be manufactured andassembled within a certain tolerance. Thus, by properly indexing thestrap ends 78 in the strap receiving grooves 62 with the ends of thestraps abutting the ends of the grooves, a consistent sandal 10 ismanufactured to design tolerances which are not usually found insandals. For example, all size 9s should be manufactured withinpermitted tolerances such that each sandal should fit essentially thesame providing uniformity in sizing. This provides the customer with aquality product that the end user can rely on from sandal to sandal.

The inner midsole 100 is preferably made of a soft, foam-like material,such as a thermoplastic synthetic resin foam, such as an ethylene-vinylacetate copolymer (EVA), thermosetting resin foam, such as polyurethane(PU), or rubber material foam, such as butadiene or chloroprene rubber.For example, in a preferred embodiment the inner midsole is a foam EVAmaterial, and more preferably phylon.

The molded rubber outsole 20 includes the toe cap 30 extending from theoutsole 20 and configured to cover the top surface 54 of at least aportion of the forefoot 46 including the toes 48. The toe cap 30prevents foreign objects such as rocks and other debris from enteringthe sandal and further provides added protection to the foot 40 fromscrapes and other contact with rocks and other items.

The molded rubber outsole 20 is configured to support the lower surfaceof the foot 40 including the heel 42, midfoot 44, and forefoot 46. Theoutsole 20 has a side surface 26 which defines the lateral and medialsides of the outsole 20.

In a preferred embodiment of the present invention, an outer midsole 110is positioned between the insole 80 and the outsole 20. The outermidsole 110 provides cushioning to the sandal 10. The outer midsole 110is preferably a shock absorbing foam-like material, such as athermoplastic synthetic resin foam, such as an ethylene-vinyl acetatecopolymer (EVA), thermosetting resin foam, such as polyurethane (PU), orrubber material foam, such as butadiene or chloroprene rubber. The outermidsole 110 can also include a natural cork material or a synthetic corkmaterial like EVA. It will be appreciated that the materials as setforth herein are not limiting and that the outer midsole 110, and thesandal 10 as described herein works with a wide range of materials. Theouter midsole 110 preferably has a hardness of approximately 40 to 60 onthe Asker C scale. However, the outer midsole 110 can be from arelatively firm foam material having a hardness of approximately of 50to 70 on the Asker C scale.

As shown in FIG. 4, the sandal straps 60 are fixed the insole 80 formingan upper 140. In a preferred embodiment of the present invention, anylon like material forms a toe cap lining 132 which is configured tofit inside the toe cap 30.

FIG. 5 shows a top plan view of one embodiment of the present invention.As shown in FIG. 5, the sandal 10 of FIG. 1 has a plurality of sandalstraps 60 which are separated by sandal openings 68 through which thefoot 40 inside the sandal 10 is exposed to the exterior of the sandal10. The sandal straps 60 and sandal openings 68 are geometricallypositioned to not only provide support and comfort, but also provides anaesthetic appearance of the sandal 10. The sandal straps 60 includes atleast one strap 132 fixed to the toe cap 30.

The straps 60 are fixed to the outsole 20 to retain the sandal 10 on thefoot 40. In a preferred embodiment, as shown in FIGS. 5 and 6, at leastone of the sandal straps 60 is fixed to the lower surface 32 of the toecap 30. It can be appreciated that in an alternative embodiment of thepresent invention, at least one of the toes straps 60 can be fixed tothe upper surface 34 of the toe cap 30, rather than the lower surface 32of the toe cap 30. The sandal straps 60 are preferably fixed to the toecap 30 by glue. However, it can be appreciated that the sandal straps 60can be fixed to the toe cap 30 by stitching or any other known method ofconstruction known to one skilled in the art.

The sandal straps 60 cover the top 54 of the foot 40. The sandal straps60 are preferably made of nylon, canvas, leather or other syntheticmaterial. In addition, it can be appreciated that the sandal straps 60can be made from a combination of nylon, canvas, leather or othersynthetic material including a lining 150 for added comfort andaesthetic appearance. In one embodiment, the sandal straps 60 are awater proof leather with an anti-odor lining 150. The sandal straps 60preferably includes a rear strap assembly 120 which supports the backportion of the heel 42 of the foot 40.

In a preferred embodiment of the present invention, the sandal straps 60have a layered construction, including a neoprene or neoprene-likelining 150 overlapping leather, synthetic leather or nylon straps. Thelining 150 is usually stitched or glued to the leather, syntheticleather or nylon outer surface of the straps 60. The lining 150 ispreferably coextensive with exposed inner surfaces of straps 60 toprovide a comfortable, cushioning contact between the foot 40 and thesandal 10.

FIG. 6 is a cross-section of the sandal of FIG. 5 taken along the lineA—A. As shown in FIG. 6, the sandal 10 includes the anatomic footbed 90,the inner midsole 100, the outer midsole 110, and the outsole 20. Theoutsole 20 includes the toe cap 30 which protects the toes 48 andforefoot 46. The toe cap 30 includes a lower surface 32 facing a topsurface 25 of the footbed 90 and spaced from the footbed 90. The lowersurface 32 of the toe cap 30 and the top surface 25 of the footbed 90forms an inner cavity 28 of the toe cap 30. The inner cavity 28 protectsthe toes 48 from foreign objects such as rocks. In a preferredembodiment, the toe cap 30 covers a top of at least one half of thelength of at least three toes 48. The footbed 90 including the innermidsole 100 is fixed entirely within the inner cavity 28 of the moldedrubber outsole 20 and between the side surfaces 26.

As shown in FIG. 6, the footbed 90 extends to the inner surface 33 ofthe toe cap 30. The upper surface 92 of the insole 80 may be contoured96 to reduce the likelihood of movement between the insole 80 and thefoot 40. For example, a gradual ridge 98 may extend along the uppersurface 92 of the insole 80 between the forefoot 46 and toe 48 regionsof the foot 40. Meanwhile in the heel portion of the sandal 10, thefootbed 90 extends to a back edge 106 of the inner midsole 100.Typically, the soft foam-like elements of the outer midsole 110 willhave a greater thickness in the heel 42 of the sandal 10 than theforefoot 46 portion, due to the fact that the heel 42 of the foot 40initially contacts the ground, before the forefoot 46.

FIG. 7 is a cross-sectional view of the sandal of FIG. 4 taken along theline B—B. As shown in FIG. 7, the plurality of straps 60 extend downwardthrough the plurality of strap receiving grooves 62 formed in the insole80 including the footbed 90 and the inner midsole 100 and to the lowersurface 84 of the inner midsole 100. The straps 60 are fixed in thestrap receiving grooves 62 by glue, stitching, or other conventionaltechniques. The outsole 20 including the outer midsole 110 is preferablyglued, cemented or otherwise adhesively secured to the lower surface ofthe inner midsole 100.

FIG. 8 shows a bottom plan view of the sandal of FIG. 1. The outsole isalso anatomically designed to conform to the natural shape of the foot.The outsole 20 is preferably manufactured from a durable material suchas molded rubber or a synthetic material having rubber-like properties.In a preferred embodiment of the present invention, the outsole 20 ismanufactured from a carbon rubber. The carbon rubber is non-marking soas to avoid those troublesome and annoying black marks that many rubbersprovide. Furthermore, the outsole 20 includes at least two colors forboth aesthetic appearance and function when rubber of differentdurometer or hardness is used.

Examples of rubber or synthetic materials for the outsole 20 includematerials with rubber-elastic properties, such as natural or syntheticrubber, synthetic resinous material made of rubber-elastic by theaddition of suitable hardeners, preferably on the basis of polyurethane,epoxy resins, or the like. The outsole 20 will have a durometer ofapproximately 25 to 75 Shore D depending on the article of footwear. Ifa soft or flexible outsole 16 is desired for certain types of sandal inwhich flexibility is a major requirement, i.e., the hardness of theoutsole 20 will generally not exceed 50 Shore D. However, if a firmeroutsole 20 is desired, a hardness of greater than 50 Shore D is oftenused.

As shown in FIG. 8, a lower surface 22 of the outsole 20 has a number oftraction elements 140 spaced about the lower surface 22 of the outsole20. In addition, a knife cut siping 142 for wet traction is incorporatedinto the outsole 20. The outsole 20 also preferably includes amulti-terrain lug sole. In addition, it can be appreciated that theoutsole 20 can be textured or roughened to improve traction.

The outsole 20 as shown in FIG. 8 is only one of several designs for theoutsole 20. For example, U.S. Design patent application Ser. Nos.29/162,882 and 29/162,883, filed on Jun. 19, 2002, show several outsoles20 that could be used with an article of footwear as described hereinand are incorporated in their entirety by reference.

FIG. 9 is a side view of the medial side (the inside of the foot) of thesandal of FIG. 1. As shown in FIG. 9, the medial side of the sandal 10includes the outsole 20, the toe cap 30, the outer midsole 110, and thesandal straps 60. The footbed 90 (not shown) and the inner midsole 100(not shown) are positioned below an upper edge 112 of the outer midsole110. The sandal straps 60 include a rear strap assembly 120 including aankle strap 122 and a heel strap 124. The ankle strap 122 and heel strap124 help retain the foot 40 within the sandal 10. The ankle strap 122and the heel strap 124 are preferably integrated into a singlecomponent. As shown in FIG. 9, the outsole 20 preferably includes cleatsor traction elements 140 on the exterior surface 38 of the outsole 20.

FIG. 10 is a side view of the lateral side (the outside of the foot) ofthe sandal of FIG. 1.

FIG. 11 is a front view of the toe cap of the sandal of FIG. 1. The toecap 30 preferably has a texture similar to that of the remainder of theoutsole 20. However, as shown in FIG. 10, the toe cap 30 can have addedtexture 156 for added protection and traction.

The toe cap 30 is preferably constructed from the same material as theoutsole 20, however, it can be appreciated that the outsole 20 and toecap 30 can be constructed from different materials. The differentmaterials can having similar properties such as hardness, flexibility,and texture or in an alternative embodiment, the toe cap 30 and outsole20 are constructed from different materials having different properties.For example, the toe cap 30 may include a synthetic butadiene rubber toprevent the toe cap 30 from oxidizing, dry out and cracking.

In one embodiment of the present invention, the toe cap 30 is reinforcedwith an additive for added protection and to prevent the toe cap 30 fromcracking. In one preferred embodiment, the additive is a fiberglassmaterial or synthetic material. It can be appreciated that the additivecan be a thermoplastic resin such as thermoplastic polyurethane (TPU) ofcomparatively rich elasticity, polyamide elastomer (PAE), ABS resin, orthe like. Alternatively, the additive can be formed from a thermosettingresin such as an epoxy resin, an unsaturated polyester resin or thelike. Meanwhile, a nylon or nylon derivative can provide addedprotection to prevent the toe cap 30 from cracking under normal wear.

FIG. 12 is a back view of the heel of the sandal 10 of FIG. 1. The heelincludes a rear strap assembly 120 including the heel strap 124.

FIG. 13 is an alternative embodiment of a sandal 200 according to thepresent invention having an open heel. The sandal 200 includes a moldedrubber outsole 20 configured to support a lower surface 50 of a foot 40including a heel 42, a midfoot 44, and a forefoot 46. The molded rubberoutsole 20 including the toe cap 30 and a plurality of straps 60 toretain the sandal 200 on the foot 40. The toe cap 30 extends from theoutsole 20 and configured to cover a top of at least a portion of theforefoot. The toe cap is molded integrally with the outsole 20. Theplurality of sandal straps 60 are fixed to the outsole 20 to retain thesandal 200 on the foot 40. At least one of the sandal straps 60 is fixedto the toe cap 32.

The sandal straps 60 include a first strap 130 which extends from thetoe cap 30 to the ankle of the foot 40. The first strap 130 is fixed tothe toe cap 30 by at least one strap. As shown in FIG. 13, the firststrap includes at least two straps which are fixed to the lower surfaceof the toe cap 30. The first strap 130 has a plurality of openings 134for receiving a plurality of side straps 136. The side straps 136 extendfrom the lateral edge 138 of the outsole/insole through the openings 134to the medial edge 139 of the outsole 20 and insole 80.

The sandal straps 60 also include an ankle strap 122 extending from thelateral edge of the outsole 20 through the opening 142 in the firststrap 130 to the medial edge of the outsole 20. The ankle strap 122 alsopreferably includes an adjustable length strap 116 that is secured tothe ankle assembly 122 by a fastener 72.

The fastener 72 is preferably a buckle, a clasp, a hook-and-loop or avelcro strap of some type to allow the sandal 10 to expand to allow thefoot 40 to enter the sandal 10 and also retain the sandal 10 of the foot40. The fastener 72 is tightened to a sufficient snugness according tothe activity. It can be appreciated that any type of fastener 72 can beused.

FIG. 14 is another embodiment of a sandal 300 according to the presentinvention having a plurality of sandal straps with a lacing system 310.The sandal 310 includes an upper 320 having a plurality of sandal straps330. The sandal straps 330 includes a plurality of side straps 332 and atongue 334. The side straps 332 extend from the lower surface of theinsole 80 through the strap receiving grooves to a position on the sideof the foot 40. The side straps 332 have an opening for receiving thelacing system 310. The tongue 334 extends from the toe cap 30 over thetop portion of the foot 40. The side straps 332 and the tongue 334 arefixed to one another by a lining. The lining is preferably an anti-odorlining form for an hydro-phobic foam. For example, the anti-odor liningcan be the Aegis™ anti-microbial lining. The sandal straps 330preferably have a layered construction, including a neoprene orneoprene-like lining 140 overlapping leather, synthetic leather or nylonstraps. The lining 140 is usually stitched or glued or a combinationthereof to the leather, synthetic leather or nylon outer surface of thestraps 330. The lining 140 is preferably coextensive with exposed innersurfaces of straps 330 to provide a comfortable, cushioning contactbetween the foot 40 and the sandal 300.

In a preferred embodiment of the present invention, the upper 320includes a toe cap liner 132. The toe cap liner 132 provides addedcomfort and protection to the toes 48. The sandal straps 330 areconnected to one another by the lacing system 310. The lacing systempreferably includes a quick lock lace system having an elastic lacestring 352 with a quick lock control device 354. The quick lock controldevice 354 allows for easy adjustment of the lacing system 310. It canbe appreciated that the lacing system 310 can be nylon, leather orsynthetic material which can be used to lace the sandal straps 330 toone another.

The tongue 342 and the back of the heel strap 350 preferably includes apull loop 356. The pull loop 356 is preferably a reflective materialsuch as the 3M™ reflective pull loop. However, it can be appreciatedthat any type of pull loop 356 can be used.

In an alternative embodiment as shown in FIG. 14, the toe cap 30includes a plurality of holes 336. The plurality of holes 336 allowwater to drain from the inner cavity 28 of the toe cap 30.

FIG. 15 is an alternative embodiment of a sandal 400 according to thepresent invention having an upper 410 having a plurality of adjustablesandal straps 420. The upper 410 includes the plurality of adjustablesandal straps 410 located over the forefoot 46 and the midfoot 44 of thefoot 40. The adjustable straps 430 preferably have a layeredconstruction, including a neoprene or neoprene-like lining 150overlapping leather, synthetic leather or nylon straps 432. The lining150 is usually stitched or glued or a combination thereof to theleather, synthetic leather or nylon outer surface of the straps 420. Avelcro strap is 440 then added to the plurality of adjustable straps 420so that the fit of the sandal can be adjusted. As with the other sandalsmentioned herein, the lining 150 is preferably coextensive with exposedinner surfaces of straps to provide a comfortable, cushioning contactbetween the foot 40 and the sandal 400. In a preferred embodiment, theadjustable sandal straps 420 include a fastener 442. The fastener 442 ispreferably a snap or hook, however, it can be appreciated that any typeof fastener 442 can be used.

In addition, the heel strap 450 can include a means for adjusting theheel strap 450. For example, as shown in FIG. 15, a quick lock device452 is used as a means for adjusting the heel strap 450. In addition, itcan be appreciated that a velcro strap or a tie of some type can be usedas the means for adjusting the heel strap 450.

FIG. 16 shows a perspective view of a mold 500 for molding an outsoleaccording to the present invention. The mold 500 includes a bottom plate510, an inner toe cap plate 540 and an outer toe cap plate 560.

The bottom plate 510 has an inner surface 512 and an outer surface 514.The inner surface 512 of the bottom plate 510 has a first cavity 516which forms the lower surface 22 of the outsole 20. A plurality ofridges 518 in the first cavity 516 form the traction elements 140 of theoutsole 20. A first mold cavity 580 is formed by the closing of theinner toe cap plate 540 onto the bottom plate 510. The first mold cavity580 forms the outsole 20 including the lower surface 22 of the outsoleand the upper surface 24 of the outsole 20. The upper surface 24 of theoutsole 20 is configured to support the lower surface 50 of the foot 40including the heel 42, forefoot 44 and forefoot 46.

FIG. 17 shows the bottom plate 510, the inner toe cap plate 540, and theouter toe cap plate 560 of FIG. 16. The inner toe cap plate 540 has aninner surface 542 and an outer surface 544. The inner surface 542 of theinner toe cap plate 540 has a pair of protrusions 546 which form theupper surface 24 of the outsole 20 and the inner cavity 28 of the toecap 30. The protrusions 546 are in the shape of the upper surface 24 ofthe outsole 20. The outer toe cap plate 560 is movable with respect tothe inner toe cap plate 540. A hinge 568 holds the bottom plate 510, theinner toe cap plate 540 and the outer toe cap plate 560 together.

FIG. 18 shows the bottom plate 510, the inner toe cap plate 540 and theouter toe cap plate 560. The outer toe cap plate 560 has an innersurface 562 and an outer surface 564. The inner surface 562 of outer toecap plate 560 and the inner surface 512 of the bottom plate 510 form asecond mold cavity 590. The inner surface 562 of the outer toe cap plate560 has a toe cap cavity 566. The toe cap cavity 566 forms the topsurface of the toe cap 30. The second mold cavity 590 forms the toe cap30 extending from the outsole 20 and configured to cover the top 54 ofat least a portion of the forefoot 46. The toe cap 30 is moldedintegrally with the outsole 20.

Optionally, the toe cap cavity 566 has a plurality of protrusions 568forming a plurality of holes 336 in the toe cap 30. The plurality ofholes 336 allow water to drain from the sandal 10 if submerged in a wetenvironment during activities including, but not limited to, kayaking,water rafting, surfing, fishing or any activity wherein the sandal 10could be submerged in a body of water.

In an alternative embodiment of the mold 500 for molding an outsole 20according to the present invention includes a false plate 600. FIG. 19shows the false plate 600 which is used to added different colors and/ordifferent materials to the outsole 20. The false plate has an innersurface 602 and an outer surface 604. The false plate 600 is configuredto be positioned between the bottom plate 510 and the inner toe capplate 540. A protruding surface 606 on the inner surface 602 of thefalse plate 600 is configured to fit inside the first cavity 516 of thebottom plate 510. The protruding surface 606 prevents a first materialfrom filling at least a portion of the bottom plate 510. Thus, theprotruding surface 606 provides a means for adding a second material ofeither a different color than the first material and/or a differentmaterial composition.

Typically, the false plate 600 is preferably used to create an outsole20 having a first color and a second color having a uniform composition.However, it can be appreciated that the false plate 600 can allow theoutsole 20 to be constructed from a first material of one compositionand a second material of a second composition. In molding an outsolehaving two different colors or different material compositions, theprotruding surface 606 prevents the first material from filling aportion of the first cavity 516 of the bottom plate 510. The false plate600 and bottom plate 510 are treated in an oven in a known manner tocure the first material. The false plate 600 is then removed, preferablyby a handle 610, and a second material is added to the first cavity 516of the bottom plate 510.

A method for the production of a molded outsole, the outsole 20 having atoe cap 30 extending from the outsole 20 and configured to cover a topof at least a portion of the forefoot 44, the toe cap 30 moldedintegrally with the outsole 20 is preformed as set forth below. Themethod preferably includes a mold 500 having a bottom plate 510, aninner toe cap plate 540, and an outer toe cap plate 560. As shown inFIG. 17, the first cavity 516 of the bottom plate 510 is filled with afirst material. The first material is preferably a curable rubber, andmore preferably a non-marking material. It can be appreciated, however,that any curable rubber or synthetic material can be used.

Once the first cavity 516 of the bottom plate 510 is filled, the innertoe cap plate 540 is closed around the bottom plate 510 as shown in FIG.18. The inner toe cap plate 540 has a handle 584 for opening and closingthe mold 500. The first mold cavity 580 is formed by closing the innertoe cap plate 540 onto the bottom plate 510. The first mold cavity 580forms the molded rubber outsole 20 including the lower surface 22 andthe upper surface 24 of the outsole 20.

An additional amount of the first material is then placed over the toecap plate 548 of the protrusions 546 of the inner toe cap plate 540.This additional amount of the first material forms the toe cap 30. Theinner toe cap plate 540 and the outer toe cap plate 560 are then closedforming the second mold cavity 590.

It can be appreciated that the toe cap 30 material can be the same asthe outsole 20 or can be a different material. In addition, an additivecan be added to the toe cap 30 to prolong the life of the outsole 20.For example, in one preferred embodiment, the toe cap 30 includes asynthetic butidine rubber to prevent the toe cap 30 from oxidizing,drying out and cracking from heat and other conditions. In addition, itis preferable that the first material and the second material arecurable rubber or synthetic compounds.

The mold 500 is then treated in an oven in a known manner to cure thefirst material. It can be appreciated that an oven temperature of about250° F. to about 300° F. is preferred. However, it can be appreciatedthat the curing temperature of the first material may vary depending onthe type of material. In addition, the mold 500 is preferably treatedfor about 5 minutes to about 15 minutes to allow the first material tocure. Once again, the curing time of the first material may varydepending on the composition of the first material.

Once the first material has cured, the mold 500 is opened and theoutsole 20 is removed. The outsole 20 preferably will be molded to theinner toe cap plate 540 and can be removed in a manner known to oneskilled in the art including by hand.

In an alternative method of molding an outsole 20 according to thepresent invention, a false plate 600 as shown in FIG. 19 is added to themold 500. The first material is placed in the first cavity 516 of thebottom plate 510 and is then covered with the false plate 600. The falseplate 600 has a protruding surface 606 which prevents the first materialfrom filling at least a portion of the bottom plate 510. The bottomplate 510 and the false plate 600 are treated in an oven in a knownmanner to allow the first material to cure. As set forth above, thefirst material is preferably a carbon rubber, and more preferablynon-marking. However, it can be appreciated that a synthetic materialalso having non-marking properties can be used.

The false plate 600 is then removed, preferably by hand using thehandles 610, and a second material is added to the first cavity 516 ofthe bottom plate 510. The second material is preferably of a differentcolor and/or different material from the first material. The secondmaterial is also preferably a carbon rubber, and more preferablynon-marking. A synthetic material can be used as well.

The inner toe plate 540 and the bottom plate 510 are then closed andadditional first material is added to the second mold cavity 590 to formthe toe cap 30. The inner toe cap plate 540 and the outer toe cap plate560 are then closed forming the second mold cavity 590. The mold is thentreated in an oven in a known manner to cure the first material and asdescribed above.

After the first material has cured, the mold 500 is removed from theoven and the outsole 20 removed from the mold 500.

During the molding process, it is desirable to have the first materialremain in the first mold cavity and the second mold cavity. However,variations in manufacturing process, settling of parts, and otherfactors can produce excess material, or seepage of material beyond itsdesired location into other areas of the mold 500. Thus, it is desirableto reduce the excess material or seepage to the greatest extentpossible. Accordingly, the excess material or seepage can be trimmed byhand or other means in order to produce a finished outsole 20 which canthan be assembled in a sandal or athletic shoe as set forth below.

The molds 500, 600 and method of manufacturing an outsole 20 configuredto support a lower surface of a foot 40, including a toe cap 30extending from the outsole 20 and configured to cover a top of at leasta portion of the forefoot 44, is not limited to sandals and theconstruction thereof. It can be appreciated that the mold 500, includingthe false plate 600, and method of manufacturing, can be used to producenot only outsoles for sandals, but athletic shoes, hiking boots, hikingshoes, running shoes and any other type of footwear that an outsole 20with a toe cap 30 is desirable.

The mold 500 for manufacturing an outsole has been described above interms of a compression mold. However, it can be appreciated that themold 500 can also be used as an injection mold in a manner known to oneskilled in the art.

A preferred method for manufacturing and assembly of a sandal 10 asdescribed herein will now be described in more detail.

The plurality of straps 60 are cut from conventional materials, such asreal or synthetic leather, nylon or rubber. The plurality of straps 60are arranged by mating pieces of materials and securing the material ina prearranged pattern as desired. For example, as shown in FIGS. 1–13,the side straps 134 of the sandal straps 60 are attached to the firststrap 130 by inserting the side straps through the opening 132 in thefirst strap 130. The straps 60 including the first strap 130, sidestraps 134 and rear assembly 120 preferably has a lining 140 of neopreneor other conventional lining material.

The lining 140 is cut from neoprene or other conventional liningmaterial, and preferably covers all exposed undersurfaces of the sandalstraps 60. The sandal straps 60 are sewn or glued, or a combinationthereof to the to the lining 140. Preferably, the inner pieces arestitched to the lining 140 around their entire periphery and the outerpieces are stitched to the lining 140 only near their lower ends.Additional conventional cushioning and lining materials can be added tothe sandal straps as desired.

In the embodiments having a rear assembly 120 including the ankle strap122 and heel strap 124, the rear assembly 120 is preferably manufacturedfrom the same conventional materials, such as real or synthetic leatheras the sandal straps. The ankle strap 122 and the heel strap 124 are cutand either glued, stitched or glued and stitched together to form therear assembly 120.

The anatomical anti-odor footbed 90 is cut from a roll of an anti-odormaterial preferably manufactured by Aegis™. The footbed 90 however, canalso be cut from a roll of nylon, leather or any other materialproviding a desirable material for a footbed 90.

The inner midsole 100 is preferably molded from an EVA material such asphylon in the shape of the inner midsole 100 by conventional moldingtechniques including compression molding and injection molding.

The insole 80 is formed by combining the pre-cut footbed 90 and themolded inner midsole 100. The footbed 90 and the inner midsole 100 arethen molded together by conventional techniques and apparatus. It canalso be appreciated that the insole 80 can be one piece mold usingconventional techniques. If the insole 80 is a one piece mold, itpreferably will have an EVA footbed 90 and inner midsole 100.

The outer midsole 110 is molded from preferably a shock absorbingfoam-like material, such as a thermoplastic synthetic resin foam, suchas an ethylene-vinyl acetate copolymer (EVA), thermosetting resin foam,such as polyurethane (PU), or rubber material foam, such as butadiene orchloroprene rubber using conventional molding techniques and apparatus.It can be appreciated that the outer midsole 110 can also include anatural cork material or a synthetic cork material like EVA.

The outsole 20 is preferably molded from rubber, carbon rubber or otherconventional outsole materials using conventional molding techniques andapparatus including injection and compression molding. However, themolding of outsole 20 is used as follows to form the toe cap 32.

The outsole 20 and the outer midsole 110 is usually glued together toform an outsole assembly 112. In an alternative embodiment, the outsole20 and the outer midsole can be molded as a single piece. If the outsole10 and the outer midsole 110 are one piece molded a carbon rubber orrubber is preferred.

The sandal 10 is assembled by passing the free ends of the side strapsinto the corresponding strap receiving grooves. The free ends of thevarious components are then secured to the lower surface of the innermidsole 100, preferably using glue, cement or other conventionaladhesives. Similarly, the rear strap assembly 120 is attached to thelower surface of the inner midsole 100 by passing the free ends of theside straps into the corresponding strap receiving grooves.

The outsole 20 and the outer midsole 110 are glued together forming anoutsole assembly 112. The plurality of straps 60 and insole 80 is thenassembled with the outsole 20 and midsole 100 by glueing or cementingthe lower surface of the inner midsole 100 to the upper surface of theouter midsole 110. The insole including the toe cap material and strapsare glued to the inner cavity of the toe cap.

The present invention is described in connection with a sport sandalhaving a sole and plurality of straps that are specifically configuredfor high-performance use. The present invention is, however, well suitedfor use in other types of sandal construction. In this application, theterms lower, top, inside, exterior, and upper are used to denotedirections relative to the geometric center of the described componentunless otherwise noted.

While the invention has been described in detail with reference to thepreferred embodiments thereof, it will be apparent to one skilled in theart that various changes and modifications can be made and equivalentsemployed, without departing from the present invention.

1. A sandal comprising: a molded rubber outsole configured to support a lower surface of a foot including a heel, a midfoot, and a forefoot; a toe cap extending from the outsole and configured to cover a top of at least a portion of the forefoot, a toe cap cover; and a plurality of sandal straps fixed to the outsole to retain the sandal on the foot, wherein at least one of the sandal straps is adjustable in tightness about the wearer's foot, and at least one of the sandal straps is fixed to the toe cap.
 2. The sandal of claim 1, wherein the toe cap includes a lower surface facing a top surface of the outsole and spaced from the outsole.
 3. The sandal of claim 2, wherein at least one of the sandal straps is fixed to the lower surface of the toe cap.
 4. The sandal of claim 2, further comprising an insole positioned on the top surface of the outsole and having a forefoot insole portion disposed between the top surface of the outsole and the lower surface of the toe cap.
 5. The sandal of claim 4, wherein the outsole has upwardly extending side surfaces extending rearwards from the toe cap and defining the lateral and medial sides of the outsole and each having an upper edge.
 6. The sandal of claim 5, wherein the insole has an upper foot supporting surface which is substantially even with the upper edges of the side surfaces of the outsole.
 7. The sandal of claim 4, wherein at least two of the sandal straps are fixed between the outsole and the insole.
 8. The sandal of claim 4, wherein the insole includes a footbed and an inner midsole.
 9. The sandal of claim 8, wherein at least two of the sandal straps are fixed between the inner midsole and the outsole.
 10. The sandal of claim 1, wherein the at least one sandal strap that is fixed to the toe cap is fixed to the toe cap by glue.
 11. The sandal of claim 1, wherein the toe cap is configured to cover a top of at least one half of the length of at least three toes.
 12. The sandal of claim 1, wherein the toe cap is reinforced with an additive.
 13. The sandal of claim 12, wherein the additive is fiberglass.
 14. The sandal of claim 12, wherein the additive is a synthetic material.
 15. The sandal of claim 1, wherein the plurality of sandal straps are separated by sandal openings through which the foot inside the sandal is exposed to the exterior of the sandal.
 16. The sandal of claim 1, further comprising an outer midsole positioned on the top surface of the outsole.
 17. The sandal of claim 16, wherein the outer midsole includes a cork-like additive.
 18. The sandal of claim 16, further comprising an insole positioned on a top surface of the outer midsole.
 19. The sandal of claim 18, wherein the outsole has upwardly extending side surfaces extending rearwards from the toe cap and defining the lateral and medial sides of the outsole and each having an upper edge.
 20. The sandal of claim 19, wherein the insole has an upper foot supporting surface which is substantially even with the upper edges of the side surfaces of the outsole.
 21. The sandal of claim 18, wherein the insole includes a footbed and an inner midsole.
 22. The sandal of claim 21, wherein the footbed includes an anti-microbial material.
 23. The sandal of claim 21, wherein the toe cap includes a toe cap liner which is fixed between the inner midsole and the outer midsole.
 24. The sandal of claim 21, wherein at least two of the straps are fixed between the inner midsole and the outer midsole.
 25. The sandal of claim 24, wherein the inner midsole has a plurality of strap receiving groves located on an edge of the inner midsole.
 26. The sandal of claim 25, wherein the strap receiving grooves extend from an edge of the insole toward an inner portion of the insole.
 27. The sandal of claim 25, wherein the strap receiving grooves intersect an upper foot supporting surface of the insole.
 28. The sandal of claim 25, wherein the inner midsole has a plurality of strap receiving grooves located on the lower surface of the inner midsole.
 29. The sandal of claim 28, wherein the strap receiving grooves each have a width substantially equal to a width of the corresponding straps and a depth substantially equal to a depth of the corresponding straps.
 30. The sandal of claim 25, wherein the plurality of strap receiving grooves are positioned on an outer edge of the insole.
 31. The sandal of claim 1, wherein the toe cap includes a toe cap liner.
 32. The sandal of claim 31, wherein the toe cap liner is fixed to the sandal straps.
 33. The sandal of claim 1, wherein the sandal straps include a plurality of openings for a shoe lace.
 34. The sandal of claim 1, wherein the outsole has a plurality of durometers.
 35. The sandal of claim 1, wherein the sandal straps are formed of a material different from the molded rubber outsole.
 36. The sandal of claim 1, wherein the sandal straps are formed separately from the outsole and the toe cap.
 37. The sandal of claim 1, wherein the toe cap is integrally molded with the outsole. 